Cutting the PVC board We nested other letters around the main panel to save material. A separate sheet was used to cut pieces for the border, the bone panel and the eight parts to make the custom post skirts.
Sanding the letter edges We use a tabletop belt sander to dress the outer edges of the letters we cut and an oscillating spindle sander to do the inside edges. Letters too small for the spindle to fit into have to be sanded by hand.
Sanding the letter edges We use a tabletop belt sander to dress the outer edges of the letters we cut and an oscillating spindle sander to do the inside edges. Letters too small for the spindle to fit into have to be sanded by hand.
Gluing up the post skirts The PVC is permanently bonded together with standard PVC pipefitting glue.
Texturing the background A nylon brush in a drill is used to sand and clean up the faux woodgrain areas. Small carving tools come in handy for removing stubborn particles.
Making the mounting bracket A welded aluminum mounting frame and brackets were used to mount the sign to the posts.
Here you can see how the mounting frame and posts are attached.
Close-up of puppy graphic

What’s it cost to produce this 4-by-5-ft. freestanding sign?

By Larry Elliott

Posted on Wednesday, October 23rd, 2019

The bone cutout and border are on the same level. The dark brown border for Dog Park is on another layer on top of the bone with the white lettering on top of that. The puppy is cut from ½-in. PVC and sits on a ½-in.-thick circle on top of the border layer. The puppy graphic is an image styled from one we found in a clipart book then modified and edited to make it into a dimensional element for the sign.

The posts are custom constructed from 5-in. square hollow PVC post covers and skirted with ¾-in. PVC board. The top edge of the sleeve skirts are capped with ready-made PVC skirts that fit over the posts and have enough lip to dress up the sleeves. These are available at most large hardware stores and from online suppliers.

All screws are stainless steel to prevent any rust from ever showing up on this custom dimensional sign. Although the paint has a limited lifetime, the sign itself will withstand many years of outdoor exposure and could be refinished in years to come.

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